Water-resistant and floatable footwear and method of manufacture therefor

ABSTRACT

A water-resistant and floatable footwear including an outsole and insole, and an upper member affixed to the sole, wherein the footwear is floatable in water. In particular, the insole of the footwear is constructed of the material “marine buoy;” that is, the insole has an inner structure and an outer coating, the inner structure being constructed of a thermoplastic resin and the outer coating being constructed of a vinyl polymer. The footwear is advantageously water-proof and provides buoyancy in water.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of pending U.S. patent applicationSer. No. 10/790,375, filed Feb. 29, 2004, which is a divisionalapplication of U.S. patent application Ser. No. 10/264,015, filed Oct.3, 2002, now U.S. Pat. No. 6,766,598 issued Jul. 27, 2004, which is acontinuation of U.S. patent application Ser. No. 09/690,552, filed Oct.17, 2000, now U.S. Pat. No. 6,508,016, issued Jan. 21, 2003, thecontents of which are hereby incorporated by reference.

FIELD OF THE INVENTION

This invention relates to footwear, in particular, lightweight andcomfortable footwear providing buoyancy in water and resistance to waterabsorption, and a method of manufacture therefor.

BACKGROUND OF THE INVENTION

Casual and lightweight shoes, particularly, sandals are known. Many ofthese shoes and sandals (hereinafter collectively referred to as“footwear”) are flexible due to the materials used to construct thesoles. However, because many of these materials are porous, suchfootwear readily absorb water and become heavy and cumbersome. Theabsorbed moisture or liquid may seep out over time causing discomfort tothe wearer, or even causing the wearer to trip or fall. Moreover, suchabsorption may stain the footwear or promote the growth of unsightly orodor-causing fungus.

To avoid some of these problems, some footwear have provided drainageholes or other drainage features which unfortunately do not prevent theabsorption of water, but simply provide an outlet for the waterabsorbed. However, seepage is not avoided, nor is the growth ofunsightly or odor-causing fungus caused by the trapped moisture.

As with recreational footwear, particularly those adapted for use inwater recreation, it is desirable to have footwear that have buoyancyand float in water. It is not uncommon for a shoe or sandal to slip offone's foot while ingressing or egressing a boat. It is also not uncommonfor a shoe or a sandal to fall into a swimming pool. Accordingly,footwear which stay afloat in water, while resistant to the absorptionof water, provide many advantages.

Another desirable feature in footwear is comfort in the areas of directcontact with the feet. While many footwear are desirably casual andlightweight, the desire to minimize weight has left many footwear withuncomfortable inner soles that lack a liner that is both comfortable andslip-resistant.

Furthermore, current fashion trends mandate footwear to come in a widevariety of colors. It is therefore desirable therefore to providefootwear which address the foregoing problems, but also be suitable toarrive in a variety of colors. In order to meet the ever-changing tastesof the marketplace, the color of the footwear should be easilyalterable.

SUMMARY OF THE INVENTION

The present invention is directed to a new and improved footwearcomprising a sole including an outsole and insole, an upper memberaffixed to the sole, wherein said footwear is floatable in water. Inparticular, the insole of the footwear is constructed of the material“marine buoy;” that is, the insole has an inner structure and an outercoating, the inner structure being constructed of a thermoplastic resinand the outer coating being constructed of a vinyl polymer. As such, thefootwear is advantageously water-proof and provides buoyancy in water.The upper members of the footwear may also be constructed of the marinebuoy material and they may be configured as a continuous strap or flapsthat are detachably attached to each other. The outsole of the footwearmay be configured in close conformity with the insole, or it may includea peripheral border extending upwardly and around said insole.

The present invention is also directed to a method for producing afootwear with an insole, an outsole and upper members, comprising thesteps of: forming the outsole, forming the insole by forming an innerstructure from a thermoplastic resin, immersing the inner structure invinyl polymer, arranging the upper members relative to the insole andthe outsole to form said footwear, securely affixing the insole, theoutsole and the upper members to each other. A step of the method mayinclude providing apertures in the insole adapted for securing the uppermembers before immersing the insole in the vinyl polymer.

The foregoing and other objects, features and advantages of theinvention will be apparent from the following more particulardescription of the preferred embodiments, taken in conjunction with theaccompanying drawings, which illustrate, by way of example, theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a footwear of thepresent invention;

FIG. 2 is a side elevational view of the footwear of FIG. 1;

FIG. 3 is top plan view of the footwear of FIG. 1;

FIG. 4 is a bottom plan view of the footwear of FIG. 1;

FIG. 5 is a cross-sectional view taken along line 5-5 in FIG. 1;

FIG. 6 is a cross-sectional view taken along line 6-6 in FIG. 1;

FIG. 7 is a perspective view of an alternative embodiment of thefootwear of the present invention;

FIG. 8 is a perspective view of another alternative embodiment of thefootwear of the present invention;

FIG. 9 is a side elevational view of the footwear of FIG. 8;

FIG. 10 is a perspective view of yet another alternative embodiment ofthe footwear of the present invention;

FIG. 11 is a side elevational view of the footwear of FIG. 19; and

FIG. 12 is a perspective view of footwear of FIG. 10, with upper membersdetached from each other.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 and 2, an embodiment of a footwear 10 of thepresent invention is shown. The footwear has a sole 12, including aninsole 14 and an outsole 16, and upper member or members (hereinafterused interchangeably) 18 affixed to and extending above the sole 12 forsecuring the footwear 10 to the wearer's foot (not shown). The uppermembers 18 may include a strap 20 and a fastening member 22 both adaptedand configured to conform to the wearer's foot. In particular, the strap20 is configured to extend above the foot and the fastening member 22 isconfigured to extend between the toes of the foot. Referring to FIGS. 5and 6, the ends 24 of the upper members of this embodiment of thefootwear 10 are securely affixed to the outsole 16 by, e.g., adhesivesor glue. As understood by one of ordinary skill in the art, the uppermembers may connected to the sole 12 by a variety of different means,including the formation of a nub at the ends 24 of the upper memberswhich are received in appropriately-sized apertures defined in the sole12, or other fastening or connecting structures.

Referring to the embodiment illustrated in FIGS. 3 and 4, the insole 14and the outsole 16 are made from flexible materials and are ofsubstantially the same configuration such that their respectiveperipheral outer edges are substantially even with each other. Theoutsole 16 may be constructed of a suitably flexible, elastomeric and/ordurable material for resisting wear while providing tread. Rubber, forexample, may be used to construct the outsole 16. In this illustratedembodiment, the outsole 16 has a substantially uniform thickness ofapproximately 3/16 inch throughout the length and width of the footwear10 (see FIG. 2). A walking surface 19 of the outsole 16 is configuredwith a pattern to provide tread and friction (see FIG. 4).

Referring to FIGS. 5 and 6, the insole 14 may be constructed of acombination of flexible materials commonly referred to as “marine buoy”to resist water absorption and provide buoyancy in the footwear. Theinsole 14 includes an inner structure 30 that may be foam-like and is atleast partially, if not substantially wholly, encapsulated in awater-proof, water-repellant and/or water-resistant sealant coating 32.The inner structure 30 is compressible and of a relatively low densitycompared to the outsole 16, such that it cushions the foot. Suitablematerials for construction of the inner structure 30 include athermoplastic synthetic resin or a thermoplastic synthetic resincontaining a plasticizer. Such a suitable thermoplastic resincomposition may comprise of the following: NBR (nature polybutadinerubber) 30% PVC (polyvinyl chloride paste resin) 30% Filler talc 12%Foaming agent 10% Plasticizer 12% Process oil  6%

The resin may be molded, trimmed, cut or otherwise configured (before,during or after curing, as understood by one of ordinary skill in theart) as desired, but preferably to conform substantially to outer shapeof the foot. The thickness of the inner structure 30; however, may be asis desirable and/or functional. In a preferred embodiment, the thicknessis substantially uniform throughout the length and the width of the sole12 at approximately 1½ inches. It is understood that the thickness ofthe inner structure 30 may be nonuniform as desirable or appropriate toconform to the shape of the foot. The inner structure 30 has a topsurface 34, a bottom surface 36 and a side surface 38 extending aroundthe outer perimeter of the inner structure between the top and bottomsurfaces.

The coating or surface 32 functions as a barrier or sealant of the innerstructure 30 to the environment. As such, the coating 32 is flexible andhas water-proofing, water-repelling and/or water-resistant properties.Suitable materials include vinyl polymer or vinyl co-polymercompositions (used interchangeably herein) which may be readily mixedwith any of a variety of color pigments for coloring the coating 32 asdesired.

As mentioned, color pigments may be added to, mixed in, and/or selectedin the vinyl polymer. Accordingly, the footwear 10 may be readilymanufactured in a variety of colors to suit the tastes of themarketplace without substantial changes in the manufacturing process orequipment. In that regard, the color of the insole may be selected topurposefully match or otherwise complement the color(s) of the uppermembers 18.

To apply the coating 32, the inner structure 30 once cured and shaped isimmersed in the vinyl polymer. As such, the inner structure 30 iseffectively encapsulated or sealed within an effective water-resistant,if not water-proof barrier. Moreover, the coating 32 so encapsulatingthe inner structure 30 provides a comfortable and slip-resistant uppersurface 33 with which the foot directly contacts when the footwear 10 isworn. Once constructed, the insole 14 and the outsole 16 are securelyaffixed to each other and preferably by means of adhesive or glue.

The upper members 18, in particular the strap 20, may also beconstructed similarly to insole 14. In that regard, as shown in FIG. 6,the strap 20 may have an inner structure 40 made of the foregoing resinand a coating 42 of vinyl polymer, whereby both the inner structure 40and the coating 42 extend along the length of the strap 20. For theaverage-sized foot, the strap 20 may have a length of approximately 9.0inches and a diameter of approximately 0.5 inches. Accordingly, thestrap 20 and the insole 14 provide a comfortable contact surface for thefoot, while also being water-resistant, if not water-proof, like theinsole 14.

As also shown in FIGS. 1 and 5, the fastening member 22 may be a stripof woven textile 23 that is configured to provide a loop through whichthe strap 20 extends. A plastic or latex tube 25 may be used to securetogether ends 44 of the fastening member.

As mentioned, the ends 24 of the upper members 18 are securely affixedto the sole 12 by adhesive or glue. In the illustrated embodiment ofFIGS. 1, 5 and 6, apertures 26 are configured in the insole 14 to permitthe ends 24 to pass through the insole 14 and come into direct contactwith the outsole 16. In that regard, the apertures 26 are configured inthe inner structure 30 before it is immersed in the vinyl polymer, sothat the apertures are, too, provided with the coating 32.

Accordingly, the footwear of FIG. 1 may be constructed substantially bythe following steps:

-   -   Step 1: providing the outsole 16;    -   Step 2: forming the insole 14, including preparing the resin        composition and configuring it into the inner structure 30;    -   Step 3: immersing the inner structure 30 in the vinyl polymer to        provide the coating 32;    -   Step 4: forming the strap 20 of the upper members 18, including        preparing the resin composition and configuring it into the        inner structure 40;    -   Step 5: immersing the inner structure 40 in the vinyl polymer to        provide the coating 42;    -   Step 6: providing the upper members 18, including arranging the        strap 20, the fastening member 22 and the tube 25 relative to        each other; and    -   Step 7: securely affixing to each other, the outsole 16, the        insole 14 and the upper members 18 by adhesive or glue.

The method of the present invention may also involve the followingsteps:

-   -   Step 2a: forming the apertures 26 in the inner structure 30        before it is immersed in the vinyl polymer.

Moreover, Steps 4 and 5 may be bypassed if the upper members 18 are notto be constructed of the marine buoy material. It is thereforeunderstood by one of ordinary skill in the art that the foregoing stepsneed not be taken in the sequence presented, nor does each step need tobe taken in manufacturing the footwear 10. The method may be altered asappropriate or desired depending on the desired configuration and/orembodiments of the footwear as described further below.

As illustrated in FIGS. 7-11, the upper members 18 may adopt anunlimited number of variations in their configuration or manner ofconstruction. The upper members 18 may take the form of two converging,relatively thin members 18 a (FIG. 7), a continuous, wider member 18 bin combination with a fastening member 22 b (FIGS. 8 and 9), or even twooverlapping (adjustable) flaps 18 c that are detachable by Velcro® pads(FIGS. 10, 11 and 12). The materials of which these upper members areconstructed may be man-made or otherwise, including pseudo-suede, nylonor nylon-based textiles, or the like. As illustrated, the apertures 26(that is, the shape and size) are configured in conformity with theparticular upper members 18 employed with the footwear.

As illustrated in FIGS. 8-11, the sole 12 may also adopt unlimitedvariations in its configuration. In these illustrated embodiments, anoutsole 44 is configured to with an upwardly extending peripheral border50 (best illustrated in FIGS. 9 and 11) surrounding the relatively lowersurface 52 on which the insole 14 sits. Thus, unlike the outsole 16 ofFIGS. 1-6 which is of a substantially uniform thickness, the outsole 44provides the peripheral border 50 which may have a thickness T ofapproximately 5/16 inch and a depth D of approximately ¼ inch.

For these other embodiment of the footwear of the present invention, themanufacturing thereof may substantially follow the steps set forthabove. Clearly, where the upper members are configured or constructeddifferently, the steps may be altered as appropriate or desired.

Although the foregoing discloses the presently preferred embodiments ofthe present invention, it is understood that the those skilled in theart may make various changes to the preferred embodiments shown anddescribed without departing from the scope of the invention. As such,the invention is defined only by the following claims.

1-9. (canceled)
 10. A method for producing a footwear with an insole, anoutsole and upper members, comprising the steps of: providing theoutsole; forming the insole by configuring an inner structure from athermoplastic resin; immersing the inner structure in a vinyl polymer;arranging the upper members relative to the insole and the outsole;securely affixing the insole, the outsole and the upper members to eachother.
 11. A method according to claim 10, wherein the step of formingthe insole further comprises: providing apertures in the innerstructure.
 12. A method according to claim 10, further comprising:forming a strap of the upper members by configuring a strap innerstructure from a thermoplastic resin; immersing the strap innerstructure in a vinyl polymer.
 13. A method according to claim 10,wherein the step of providing the outsole further comprises: forming anouter peripheral border.
 14. A method according to claim 10, furthercomprising: adding a color pigment in said vinyl polymer.
 15. A methodaccording to claim 14, further comprising: changing the color pigment insaid vinyl polymer.
 16. A method according to claim 14, wherein saidthermoplastic resin composition comprises nature polybutadine rubber,polyvinyl chloride past resin, filler talc, foaming agent, plasticizerand process oil.
 17. A method according to claim 14, wherein said vinylpolymer includes a color pigment selected in accordance with a color ofthe upper members.
 18. A method for producing a footwear with an insole,an outsole and upper members, comprising of: providing the outsole;forming the insole by configuring an inner compressible structure tohave a top surface, a bottom surface and a side surface extending aroundthe perimeter of the inner structure between the top and bottomsurfaces; immersing the inner structure in a vinyl polymer to form anouter coating that is a water barrier; arranging the upper membersrelative to the insole and the outsole; securely affixing the insole,the outsole and the upper members to each other.
 19. The method of claim18, wherein the inner compressible structure is a different materialthan the outer coating.
 20. The method of claim 19, wherein the innercompressible structure is a thermoplastic resin.
 21. The method of claim19, wherein the inner compressible structure is a thermoplastic resinthat compresses to cushion a foot of a wearer.
 22. The method of claim19, wherein the inner compressible structure is a thermoplastic resinthat compresses to generally conform to a shape of a foot of a wearer.23. The method of claim 18, wherein the inner compressible structure hasa low density relative to the outsole.
 24. The method of claim 18,wherein the inner compressible structure is a single layer ofcompressible material and the outer coating contacts the top and sidesurfaces of the compressible structure.
 25. The method of claim 18,wherein the footwear is buoyant.
 26. The method of claim 18, wherein theoutsole is wear resistant relative to the insole.
 27. The method ofclaim 18, wherein the inner compressible structure is compressiblecompared to the outsole.
 28. The method of claim 20, wherein thethermoplastic resin contains plasticizer.
 29. The method of claim 18wherein immersing forms a seamless continuous layer that substantiallycovers the entire top, bottom and side surfaces of the compressiblestructure.
 30. The method of claim 10, further comprising providingaperatures in the inner structure before immersing the inner structurein the vinyl polymer.
 31. The method of claim 18, further comprisingproviding aperatures in the inner structure before immersing the innerstructure in the vinyl polymer.
 32. The method of claim 10, wherein thethermoplastic resin comprises rubber and PVC.
 33. The method of claim18, wherein the inner compressible structure comprises rubber and PVC.